Assembly material flow system and method thereof

Abstract

Assembly material handling systems and methods include a collective component storage area and an assembly area, each including aligned rack aisles for the selective positioning of predetermined full containers and depleted component empty containers. A plurality of transfer vehicles movable along material aisles directly adjacent to the rack aisles shuttle between the component storage area and the assembly area to retrieve and deposit full and empty component storage containers to support the assembly of at least one product in the assembly area. In an example, the component storage area includes a large component storage area, a small component storage area, and a consumable material storage area. In an alternative example, the transfer vehicles include first and second supports to simultaneously support and transfer full component containers and empty component containers to increase material handling efficiency.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to material logistics to support and conduct assembly operations of products, such as passenger vehicles. BACKGROUND

[0002] Product manufacturers are under increasing pressure to manufacture and assemble products efficiently and cost effectively. This is particularly acute in the assembly of passenger vehicles by original equipment manufacturers (OEMs) and their suppliers. To remain competitive, manufacturers must strive to increase production with fewer assembly facilities and resources. Significant advances in technology have helped these efforts, but improvements are needed and require suppliers of logistics and assembly systems used to assemble products to continually improve.

[0003] Conventional assembly facilities and systems have made progress in many aspects of product assembly. In many assembly subsystems, the use of automated robots, automated guided vehicles (AGVs), and conveyor systems have reduced many manual-intensive tasks, such as material handling of heavy objects and welding of components and subcomponents.

[0004] Conventional assembly facilities continue to have significant disadvantages in facility layout and material logistics to support efficient, high-volume manufacturing of precision products, such as passenger vehicles. Conventional assembly facilities continue to be designed to include discrete assembly areas or production lines for certain operations that place them in areas of the facility that are remote from other assembly areas. These remote assembly areas then require the transport of partially completed products to other remote areas of the facility where further assembly operations are performed. These transport devices are complex, expensive, and disrupt the continuous efficient assembly process.

[0005] Conventional assembly facilities also include disadvantages in flexibility of the assembly environment to adapt to changes in products to be manufactured. When a product or product model changes to support a product order, it takes hours or even days to change the material logistics and equipment to adapt to the product change, resulting in increased facility or assembly line downtime and inefficiencies.

[0006] Conventional assembly facilities also include further disadvantages in systems and devices used to provide subcomponents and components to various discrete assembly lines and processes. Although progress has been made to provide a continuous supply of components and consumable materials to assembly lines to support assembly operations, the logistics devices and methods used to supply components and materials to assembly lines encounter obstacles and include repetitive processes and movement of equipment that result in unnecessary delays and other defects that reduce product throughput.

[0007] Improvements are needed in the logistics material storage, handling, and supply of materials and components to support high-volume and efficient operating product assembly facilities. SUMMARY

[0008] Disclosed herein are systems and methods for logistics handling of assembly components and consumable assembly materials to support assembly operations in high volume assembly facilities. In one example application, the methods and systems are useful in passenger vehicle assembly facilities.

[0009] In one example, an assembly material logistics system includes a marketplace component storage area operable to temporarily store a plurality of component containers, each container supporting at least one component, the storage area having a rack aisle extending in an x-direction. An assembly area is located downstream of the storage area and includes at least one assembly line operable to assemble at least one product comprising at least one component. The component storage area and the assembly area each include a rack aisle extending in the x-direction, aligned with each other. The rack aisles are used to position full and empty component containers for engagement and transfer by a transfer vehicle.

[0010] An example system includes a material aisle directly adjacent and parallel to the storage area rack aisle and the assembly area rack aisle. A plurality of transfer vehicles selectively and reciprocally move along the material aisle between the storage area and the assembly area. The plurality of transfer vehicles are each independently operable to selectively engage at least one full or empty container in the storage area rack aisle or the assembly area rack aisle. The transfer vehicles transfer the engaged at least one full component container or empty component container between the storage area and the assembly area and selectively disengage the at least one full component or empty component container in the storage area rack aisle or the assembly area rack aisle to support assembly of at least one product in the assembly area.

[0011] In other examples of the system, the marketplace storage area includes a large component container storage area including a display row storage rack located in the rack aisle. In other examples, the storage area includes small component storage areas and consumable material storage areas adjacent to each other and each storage area includes a portion of the rack aisle.

[0012] In other examples of the system, the transfer vehicles include first and second supports operable to independently engage or disengage full or empty containers in the storage area and the assembly area and transfer the engaged full containers and empty containers between the storage area and the assembly area.

[0013] In other examples of the system, the assembly area includes at least two assembly cells including a portion of the assembly area rack aisle. The assembly area includes a plurality of programmable robots operable to selectively engage components and move them from the assembly area rack aisle into the assembly line for progressive assembly of at least one product.

[0014] An example of a method for assembling a material flow includes a consolidation storage area upstream of an assembly area operable to store a plurality of component containers including at least one component. The method includes selectively positioning a predetermined full component container in a storage area rack lane extending in an x-direction. One of a plurality of transfer vehicles is positioned in a material lane directly adjacent and parallel to the rack lane. The transfer vehicle selectively engages one of a plurality of predetermined full component containers from the storage area rack lane and removes the full component container from the storage area rack lane.

[0015] The example method further includes transferring the full component container by the transfer vehicle downstream of the material lane to the assembly area. The same or a companion transfer vehicle selectively engages an empty component container positioned in an assembly area rack lane and removes the empty component container from the assembly area rack lane in alignment with the storage area rack lane. The transfer vehicle deposits the engaged and transferred full component container into the assembly area rack lane to support assembly of at least one product.

[0016] In an example of the method, the transfer vehicle transfers the empty container along the material lane for depositing the empty container in the storage area for replenishment. The transfer vehicle then engages a predetermined full component container for transfer to the assembly area to begin a next component supply cycle.

[0017] These and other aspects of the present disclosure are disclosed in the detailed description of the embodiments below, the appended claims, and the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0018] The present application is best understood when read in conjunction with the accompanying drawings using the following detailed description. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.

[0019] FIG. 1 is a schematic top view of an example of an assembly site showing a plurality of assembly lines of the present application.

[0020] FIG. 2 is an example of a left front perspective view of an example of a material flow system including one assembly line of the present application.

[0021] FIG. 3 is a schematic top view of a portion of the example of FIG. 2.

[0022] FIG. 4 is a schematic view of an example of operation of two alternative component container transfer vehicles.

[0023] FIG. 5A is a perspective view of an example of a component container transfer vehicle.

[0024] FIG. 5B is a perspective view of an alternative example of a component container transfer vehicle component.

[0025] Figure 6A is a perspective view of an alternative example of a component container transporting a vehicle component.

[0026] Figure 6B is a perspective view of an alternative example of a component container transporting a vehicle component.

[0027] Figure 7A is a perspective view schematic of an example of an alternative component container transporting vehicle.

[0028] Figure 7B is a schematic top view of the example transporting vehicle of Figure 7A.

[0029] Figure 8 is a schematic top view of a portion of Figure 2.

[0030] Figure 9 is a right rear perspective view of a portion of Figure 2.

[0031] Figure 10 is an enlarged left front perspective view of a portion of Figure 2.

[0032] Figure 11 is a perspective view of an example of a component container.

[0033] Figures 12A-12C are schematic views of alternative positions of a transporting vehicle.

[0034] Figure 13 is an enlarged perspective view of a portion of Figure 2.

[0035] Figure 14A is a perspective view of an example of a transporting tray.

[0036] Figure 14B is a perspective view of the transporting tray of Figure 14A including an example component.

[0037] Figure 15 is an enlarged perspective view of a left front portion of Figure 2 showing an example assembly area including an assembly line.

[0038] Figure 16 is a right front perspective view of Figure 15.

[0039] Figure 17 is an example of an alternative assembly area including an example mobile detection security system.

[0040] Figure 18 is a schematic view of an example of a control system.

[0041] Figure 19 is a schematic flow chart of an example of a method of the present invention.

[0042] Figure 20 is an example schematic view of an assembly logistics control and monitoring system.

[0043] Figure 21 is a left perspective view of an implementation example of the assembly logistics control and monitoring system of Figure 20. DETAILED DESCRIPTION

[0044] Referring to FIGS. 1-21, an example and method of assembling a material flow system 10 is shown. In one example application, the system and method can be used in a high volume passenger car assembly plant. It should be understood that the present application has many other applications for assembling and / or manufacturing other products, including but not limited to consumer goods and other commercial and industrial applications.

[0045] Referring to FIG. 1, an example of a plan layout of a vehicle assembly plant 12 for assembling a passenger car body or body-in-white structure is shown. The example includes the assembly of a passenger car sheet metal body, followed by the attachment of powertrain, suspension and interior components to the body. As previously mentioned, the system 10 has other applications for vehicle assembly and non-vehicle products.

[0046] In one example of the system and method 10, the local and / or central control system, discussed further below, includes an automated or computerized product build schedule program (not shown) that communicates with the automated equipment and devices in the system 10, such as the storage racks of the assembly storage area, the automated transfer vehicles and / or the automated robots and assembly line transfer conveyors of the assembly area, all of which will be discussed further below. In one example, the build simulation and / or component schedule computer program monitors and controls the type of vehicles or products to be assembled within a predetermined time period, such as a work shift. An example build schedule plan also includes the specific order or sequence of products to be built, for example, 100 vehicles of model A, then 50 vehicles of model B, then 75 vehicles of model C, then 25 vehicles of model A.

[0047] In one example of the system and method 10, the example component schedule program also monitors and / or controls the assembly of vehicles or other products in the assembly area according to a predetermined component schedule established for a work shift. One goal of the system and method 10 is to receive, temporarily store and supply components to the assembly area to support the predetermined assembly runs of the predetermined vehicles or other products established and / or input to the build assembly plan on a continuous and timely basis.

[0048] In the example of the system and method 10 of FIG. 1, the example plant 12 includes an external loading dock and an internal warehouse area 16 in which a semi-trailer or other vehicle transports a large quantity of assembly components, consumable materials used in the assembly process. These materials and other equipment are transported, unloaded and temporarily stored in the warehouse area 16 as needed. An example of a plant layout and an example of operations in the loading dock and temporary warehouse or storage area 16 are disclosed in U.S. Patent No. 8,869,370, assigned to the assignee of the present application and incorporated by reference. Other areas and configurations of the warehouse area 16 can be used as known by those skilled in the art.

[0049] Referring to FIGS. 1 and 2, the example system and method 10 includes a consolidated component set container storage area 20 and an assembly area 24, discussed further below. In the example site 12 of FIG. 1, the assembly area 24 includes a plurality of assembly lines 26 (nine are shown) oriented substantially parallel to each other, each line 26 including an assembly travel path 30 in which a product (e.g., a vehicle body) is progressively assembled in a series of sequentially positioned assembly cells 34. Each assembly cell 34 includes one or more assembly operations, such as welding components or subassemblies to a progressively built vehicle body by programmable multi-axis robots, discussed further below. In one example for an assembly area 24 for assembling a white body structure, the assembly lines 26 can include a vehicle body floor sub-assembly line, a vehicle body floor main assembly line, a vehicle body floor respot line, a vehicle body side assembly line, and a vehicle body frame assembly line. As known to those skilled in the art, the assembly lines 26 can be designed, configured, oriented, and functioned to accommodate particular applications.

[0050] While FIGS. 1 and 2 show the warehouse area 16 and the storage area 20 in close proximity and in-line alignment with the assembly area 24, it should be understood that these areas 16, 20, and 24 can be in different locations and orientations relative to each other within the site 12 to, for example, accommodate existing floor footprints, existing site structures, and predetermined assembly processes and operations of the site 12 building. It should also be understood that the number, relative location, and orientation of the assembly lines 26 can vary, increase, or decrease to accommodate particular applications and performance specifications, such as the number of jobs or product builds required per hour. Other systems 10 and site 12 structures, locations, and configurations can be used that accommodate particular applications known to those skilled in the art.

[0051] Referring to the example of the system and method 10 of FIGS. 2, 5, and 6, the material flow system 10 uses one or more, and in some examples, a plurality of transfer vehicles 40 to engage and transport a plurality of component containers 44 or consumable materials from the consolidated storage area 20 to the assembly area 24, as described further below. In the example system and method 10, the containers 44 referred to include open, partially open, partially closed, or fully closed containers, conventional pallets, platforms, and other structures used to support and / or contain components. It should be understood that a component container can contain a single component or item, or a plurality of components. As used herein, a full container is referred to as a container having at least one component supported by the container that is intended for use in assembling at least one product in the assembly area. An empty container is referred to as a container that is depleted of all components or a sufficient number of components such that it is considered depleted or needs to be replaced with a full container to support an assembly operation by business practice or process.

[0052] The components referred to include individual components or parts, sub-assembly components, consumable assembly materials, fasteners, and / or items used directly in the assembly process or indirectly by assembly equipment or operators to support assembly operations. It will be appreciated that consumable materials can include a wide range of materials used in the assembly process, such as mechanical fasteners, adhesives, paint, sealants, and other fluids, as well as other items used directly in the assembly process to accommodate particular applications and / or as known to those skilled in the art. Consumable assembly materials can also include materials used by equipment or operators to support or maintain the assembly process and / or assembly equipment, including water, lubricants, consumable welding or material joining materials, as well as other physical items and fluids used in the assembly process as known to those skilled in the art.

[0053] As best shown in FIGS. 3 and 4, the exemplary system 10 includes a material aisle 50, a rack or component container aisle 56, and a pedestrian aisle 60, as generally shown. In the example shown, and as more fully described and shown below, the rack aisle 56 is an aisle, pathway, and / or area in which component containers 44 are selectively positioned and temporarily stored within the collective storage area 20 and assembly area 24 within the range of engagement or extension of the transfer vehicles 40 positioned and movable along the material aisle 50. As best shown in FIGS. 2, 3, in a preferred, but not exclusive example, the rack aisle 56 is a portion of the storage area 20 and assembly area 24 that extends from the collective storage area 20 in the x-direction 64 through the assembly area 24. In a preferred example, the rack aisle 56 extends in a substantially straight aligned manner from the material collection area 20 through the assembly area 24. In one example, the rack aisle 56 is substantially parallel to the adjacent assembly line 26 and travel path 30. It will be appreciated that the rack aisle 56 can take on other positions, locations, orientations, and alignments relative to the storage area 20 and assembly area 24 to accommodate particular applications and performance specifications as known to those skilled in the art.

[0054] Referring to the example of FIGS. 3 and 4, the material passageway 50 is a passageway, pathway, and / or area positioned directly adjacent to and substantially parallel to the rack passageway 56. As discussed further below, the material passageway 50 has sufficient width and length to allow the transfer vehicles 40 to pass along the passageway 50 and travel between the storage area 20 and the assembly area 24, as generally shown. In one example, the width of the material passageway 50 (in the y-direction 140) is only sufficient to accommodate a single transfer vehicle 40 (not enough to accommodate two transfer vehicles side-by-side) to minimize the footprint of the facility 12. In another example, the width of the material passageway 50 is sufficient to have two or more transfer vehicles 40 located side-by-side (in the y-direction 140) in the material passageway 50, allowing the transfer vehicles 40 to pass by or around other transfer vehicles 40 located in the material passageway 50 without the vehicles 40 entering the rack passageway 56 or the pedestrian passageway 60. It should be appreciated that different material passageway 50 widths can be used to accommodate particular application and performance requirements known to those skilled in the art.

[0055] The example system 10 also includes a pedestrian passageway 60 for allowing human operators and technicians to walk or travel or briefly stop along the collection area 20 and the assembly area 24 without impeding the movement of the transfer vehicles 40 along the preferably directly adjacent and substantially parallel material passageway 50. In one example (not shown), the pedestrian passageway 60 is not included in the system 10. In another example (not shown), the rack passageway 56, the material passageway 50, and / or the pedestrian passageway 60 can be positioned on both sides of the collection storage area 20 and / or the assembly area 24 to increase the flow of components to the assembly area 24 to support operations. It should be appreciated that alternate numbers, positions, relative positions, configurations, lengths, widths, and / or orientations of the material passageway 50, the rack passageway 56, and / or the pedestrian passageway 60 can be used to accommodate application and performance requirements known to those skilled in the art.

[0056] Referring to FIGS. 5, 6, and 7, examples of transfer vehicles 40 are shown that are operable to engage and transport a plurality of component containers 44 along material passages 56 to support assembly operations in the assembly area 24 in accordance with a build schedule. Referring to FIG. 5A, an example of an automated transfer vehicle 40A is shown. The example transfer vehicle 40A includes a body or housing 70 that includes a rigid, load-bearing internal frame (not shown). The transfer vehicle 40A includes an on-board control system 80 that includes components shown generally and further described below in FIG. 18. In a preferred example, the transfer vehicle 40A is an automated guided vehicle (AGV) that is autonomously driven and guided using a wireless digital data communication and navigation system that includes a transmitter / receiver antenna 86, 444 and one or more sensors 88, 428. In one example, the transfer vehicle 40A includes on-board software and programmed instructions in the on-board control system 80 that allow the vehicle to autonomously move along the material passages 50 and selectively engage / disengage the component containers 44 generally described herein to support assembly build operations. In another example, each transfer vehicle 40A receives digital data signals from a local or central control system 326, 616 that are processed by the vehicle 40A on-board control system 80 for moving and guiding the vehicle 40A through predetermined movements and operations generally described herein.

[0057] It should be understood that the term autonomous includes both fully autonomous and semi-autonomous operations. In one example, fully autonomous includes a vehicle 40A that does not have an on-board operator and that moves and navigates without human intervention or manual control in normal operations. Examples of fully autonomous transfer vehicles 40A, 40B, 40E are shown in FIGS. 5A, 5B, 7A, and 7B. One or more of the transfer vehicles 40 can also be semi-automated or manually operated. Examples of manually or semi-automatically operated transfer vehicles 40 are shown in FIGS. 6A, 6B as 40C and 40D. In these examples, the vehicles 40C and 40D can be configured to support a human operator on the vehicle body 70 to oversee autonomous movement and navigation of fully autonomous vehicles as described above, or to selectively intervene and / or manually control certain operations or movements of the vehicle 40. Alternatively, the vehicles 40C and 40D can be manually operated in a conventional manner like a traditional forklift.

[0058] The example transport vehicles 40A, 40B also include at least two powered wheels 90, in one example four wheels, rotatably connected to the vehicle body 70 and engaged with an actuator 432 (FIG. 18), such as an electric motor powered by an on-board rechargeable battery 448, to propel the vehicle 40A along the material passageway 50 along a predetermined path. In a preferred example described further below, the vehicle 40A includes a mode of operation in which movement of the vehicle 40A is limited to substantially straight linear movement along the x-direction 64 along the material passageway 50 and between the consolidated storage area 20 and the assembly area 24. It is further understood that the autonomous vehicles 40A, 40B can also include movement and navigation capabilities to move and navigate around other transport vehicles 40 located in the material passageway 50, or other objects located in the predetermined travel path of the vehicles 40A, 40B.

[0059] It is understood that alternative modes of operation or movement can allow the vehicles 40A, 40B to turn omnidirectionally, laterally and / or negotiate, such as to exit or move away from the material passageway 50 for maintenance, charging, reprogramming or other activities known to those skilled in the art. In examples where the site 12 is not configured in a generally straight linear and parallel manner as shown in FIG. 1, the transport vehicles 40 can be operable to move along non-linear or curved paths to accommodate the particular orientation of the site 12.

[0060] Referring to FIGS. 5A and 6A, examples are shown of the transport vehicles 40A and 40C each having a first support 110, 110A (collectively first support 110) and a second support 114, 114A (collectively second support 114). The example vehicle body 70A in FIG. 6A is configured alternately to include a cab 70A for housing an operator (not shown) to manually control one or more aspects of the vehicle 40C, such as movement of the vehicle along the material passageway 50 and to manipulate the first support 110 and the second support 114 to engage and disengage the containers 44 described herein.

[0061] In the example, the first support 110 and the second support 114 of each transport vehicle 40A, 40C can each independently engage, support, disengage and move a container 44 (not shown) positioned on the respective support along the y-direction 140 and the z-direction 134 relative to the vehicle body 70. Movement of the supports in the y-direction 140 toward and away from the rack passageways 56 and in the z-direction 134 perpendicular is by one or more actuators 432, such as electric and / or hydraulic motors, in communication with the vehicle on-board control system 80. In this example, both the first support 110 and the second support 114 are positioned in the same direction to engage a container 44. It is understood that either the first support 110 or the second support 114 can face in the opposite y-direction 140 to, for example, engage a container 4 positioned in a rack passageway 56 located on either side of the material passageway 50.

[0062] Referring to FIGS. 5B and 6B, alternative automated or manual transfer vehicles 40B and 40D (collectively, vehicles 40B) are shown. In the example, the vehicles 40B include only the first support 110A. The alternative configured transfer vehicles described include similar, albeit alternative, structures and / or configured components and functionality, including the same reference numbers as described for the vehicles 40A and 40C. The structure and operation of the vehicles and the first support 110A are otherwise similar to the description of the first support 110 for the transfer vehicles 40A, 40C. It will be appreciated that the transfer vehicles 40 can take other forms, sizes, configurations, functionality, and / or movements to move along the material path 50 and engage, support, move, and disengage the containers 44 described herein to accommodate particular applications and performance specifications as would be known to those skilled in the art.

[0063] Referring to FIGS. 7A and 7B, an alternative example of a transfer vehicle 40E is shown. Referring to FIG. 7A, the example transfer vehicle 40E is also an AGV that includes autonomous or semi-autonomous (collectively, autonomous), driving, and navigation capabilities as described above for the transfer vehicle 40A. In an example, the example vehicle 40E includes an on-board control system 80 including sensors 86 as described above for the vehicle 40A. In an example, the vehicle 40E includes a base 146 and powered wheels 90 in communication with the control system 80 as generally described for the vehicle 40A. As best shown in the example of FIG. 7B, a first support in the form of a first set of powered rollers 148 and a second support in the form of a second set of powered rollers 149 are in rotatable engagement with the base 146. Each of the first set 148 and the second set 149 are in communication with a separate drive actuator 432 (shown schematically in FIG. 18) that allows each of the first set 148 and the second set 149 to be selectively rotated independently of one another as shown in FIG. 7B. The drive actuators 432 are in communication with the control system 80.

[0064] The transfer vehicle 40E is shown in the example of FIG. 7B placed in the assembly area 24 for depositing full component containers 44, for example, in the rack passageways 56 of the assembly units 34, and receiving empty containers 44 from the rack passageways 56 in the assembly units 34. In the example shown best in FIG. 7B and FIG. 15, a stationary support tray or rack 150 is placed in the assembly area 24 or the rack passageways 56 of the assembly units 34 and includes a similar first set and second set of powered rollers that are in communication with a separate control system 80 to independently power the rollers that support the rack 150.

[0065] Referring to FIGS. 7A and 7B, an exemplary use and operation of a transport vehicle 40E is shown. In this example, the vehicle 40E is used to support and autonomously transport a full parts container 44 from the consolidated storage area 20 to an assembly cell 34 of the assembly area 24. Once at the predetermined location in the assembly area 24, the vehicle 40E can activate the first set of rollers 148 and the second set of rollers 149 in sequence or simultaneously, by sensors 86 or other means, for example, at the predetermined assembly cell 34, aligning in the x-direction 64 and directly adjacent in the y-direction 140, positioned on the support tray 150. In this example, the first set of rollers 148 rotate to move the full parts container 44 onto the support tray 150 and receive the empty parts container 44 from the support tray 150 onto the second set of rollers 149. In this example, the local or central control system 326 can wirelessly signal and coordinate or control the activation / deactivation of the rollers 148, 149 and support tray 150 on the respective vehicle 40E to achieve the predetermined transport of the container 44, as explained.

[0066] Similar examples of the function and use of the vehicle 40E are in the consolidation 20. For example, the large parts storage racks 162 can include powered rollers in the carriers 80 as further described below. In an example, the lowest row of the presentation rows 182 (FIG. 10) in the rack aisle 56 can include powered rollers similar to those described for the support tray 150. The vehicle 40E will receive a full parts container 44 and transport an empty parts container 44 into the rack 162, or to the storage areas 166 or 170 described further below, alternatively. In an example (not shown), a vertical lift or other lifting device can be used to raise and lower the vehicle 40E or a portion thereof to reach higher rows in the rack 162. Other applications, vehicle structures, sizes, configurations, motions, and processes of the vehicle 40E can be used as known to those skilled in the art.

[0067] Referring to FIGS. 8 and 9, an example of the consolidated parts storage area 20 is shown. The storage area 20 is operable to temporarily store and organize parts for use in assembling at least one product in the assembly area 24. As best shown in the FIGS. 2, 8, and 9 examples, three separate storage areas are used, a first or large parts container area or rack 160, a second or small parts or small container area or rack 166, and a third or consumable material storage area 170. In this example, either the first storage area 160 or the second storage area 166 can be either of the two of the three areas 160, 166, 170, depending on the particular application and performance requirements. Alternatively, only a single or two (not shown) of the storage areas 160, 166, or 170 can be used.

[0068] Referring to FIGS. 2, 9, 10, and 11, an example of a large part or container storage area 160 in the form of a large part storage rack 162 can be used for temporary storage and staging of large part containers 44A. In a high or high volume output assembly site 12, multiple large part containers 44A can be used to store larger sized parts, for example, which are typically placed in custom or standardized storage racks or pads, such as the automobile door panel shown in FIG. 11. Although described as storing large parts and containers 44A, it should be understood that the area 160 and rack 162 can be used for smaller sized parts and other items to suit a particular application. For example, large quantities of small parts, such as hundreds or thousands of mechanical fasteners, can be contained in a large container 44A. Alternatively, smaller sized containers, such as 44B described below, can be stored in the storage rack 162.

[0069] In the example best seen in FIG. 10, the storage rack 162 includes a load bearing frame that includes vertical supports and shelves that divide the rack 162 into a plurality of bays 180 that extend from a display row 182 located in the rack aisle 56 and directly adjacent to the material aisle 50, as shown in FIGS. 8 and 10. In the example rack 162, each bay 180 includes a width 184 and a height sufficient to pass a large part container 44A and at least a portion of a transfer vehicle 40 so as to enter and pass through such that the first support 110 and the second support 114 of the transfer vehicle 40 can engage and disengage the part container 44A.

[0070] In examples where the transfer vehicle 40 is autonomous, one or more sensors 86 located on the transfer vehicle 40 (in communication with the vehicle control system 80), and / or a local or central site control system 326, 616 can be used to locate the transfer vehicle 40 and align with the storage rack 162. In examples, an autonomous transfer vehicle 40A is moved and positioned in alignment with a predetermined bay 180 having a predetermined full part container 44A (required for assembly runs in a predetermined assembly cell 34). The predetermined full container 44A is positioned in the display row 182 and rack aisle 56 of the rack 162 ready to be engaged and removed from the rack 162 by the aligned transfer vehicle 40A. Other vehicles 40A or additional sensors or equipment to assist and / or confirm alignment or engagement can be used as known to those skilled in the art. Although described using autonomous transfer vehicles 40A, it should be understood that the other transfer vehicles 40B-40E described, as well as other AGVs and manual devices for moving containers, can be used in the described manner as known to those skilled in the art.

[0071] As best shown in FIG. 10, an example of a large component container rack 162 includes a first area 200 (the first two rows of vertical racks 180) for storing and staging full component containers 44A, 204 that can be selectively moved in the y-direction 140 toward the display rows 182 and rack aisles 56. The example rack 162 also includes a second area 210 (the third vertical row shown in FIG. 10) for storing and staging empty or depleted component containers 44A, 214 that can be moved in the y-direction away from the display rows 182 and rack aisles 56 toward an exit row 216, as generally shown in FIG. 10. In an example of a storage rack 162, the exit row 216 temporarily houses or stages empty component containers 44A for removal from the rack 162, as further described below. Using the storage rack 162 and the first area 200 and the second area 210, there is provided an efficient and orderly area for temporarily storing full component containers 44A, 204 to be sequentially transported to the assembly area 24 and efficiently collecting, temporarily storing and staging empty component containers 44A, 214 for replenishment of components at another area of the facility or back to a supplier for replenishment of components.

[0072] In an example of the system and method 10, a storage rack 162 (a device mounted on a rack or carriage 180) is included to facilitate movement of large component containers 44A within the storage rack 162, such as toward the rack aisles 56 / display rows 182 or the exit row 216. For example, idler or powered rollers (not shown) can be used to move respective containers 44A (full 204 or empty 214) in the respective y-direction 140. In an example, sensors 84, 426 in communication with the example rack powered rollers and a local or central control system 326, 616 can be used to monitor and selectively move containers 44A, 204, 214 within the rack 162 to facilitate storage, staging and removal of containers 44A within the rack 162, such as to place full containers 204 in the display rows 182 / rack aisles 56 described.

[0073] In an example, full component containers 44A, 204 are selectively removed from the display rows 182 in the rack aisles 56 by the transfer vehicles 40. As generally shown in the FIG. 8 example, empty component containers 44A, 214 are removed by a second transfer vehicle 224 from the exit row 216 of the storage rack 162 on the opposite side of the material line 50 from the back side of the storage rack 162 so as not to interrupt the delivery of components to the assembly area 24 to support the assembly operation. The second transfer vehicle 224 can be the same structure as the transfer vehicles 40A-E or can alternatively be a conventional forklift or other manual, automated or autonomous lifting device known to those skilled in the art.

[0074] Referring to FIG. 4, an exemplary use of a transfer vehicle 40 is shown, which is in the form of a first support 110 and a second support 114 (transfer vehicles 40A, C and E). In the example, in one pass or cycle at a storage rack 162, the transfer vehicle 40A can first engage and remove a full large part container 44A, 204 from a first area 200 of the storage rack 162, a display row 182 in the rack aisle 56, and move / index and almost immediately deposit an empty large part container 44A, 214 in a display row 182 in a second area 210 of the storage rack 162, in the rack aisle 56. Alternatively, two full part containers 44A, 204 can be engaged in one cycle or two empty part containers 44A, 214 returned to the storage rack 162. This results in higher efficiency and throughput as compared to a transfer vehicle having only a single first support 110 (FIGS. 5B and 6B). In an example (not shown), the empty container 44A, 214 can be deposited into the rack 162 at another area of the rack 162, such as directly into the exit row 216, or a storage area of the other area 20.

[0075] FIGS. 4 and 12A, 12B and 12C show an exemplary sequence in which the transfer vehicle 40A picks up or engages a full part container 44A, 204 from a storage rack 162, secures and transports the full part container 44A to an assembly area 24, and moves an empty part container 44A, 214 from the assembly area 24 back to the storage rack 162 for deposit into the storage rack 162. Alternatively as described above, the engagement of the full part container 44A, 204 and the drop off / deposit of the empty part container 44A, 214 occur almost simultaneously on the storage rack 162. Alternatively, the full part container 44A, 204 can be dropped off / deposited from the rack aisle of the assembly area 24 in a similar manner, while the empty part container 44A, 214 can be engaged / picked up from the rack aisle 56 of the assembly area 24 in a similar manner.

[0076] In the example shown in FIG. 4 and FIG. 12A, the transfer vehicle 40 itself transports the full container 44A, 204 retrieved from the storage rack 162. In an example, when it is detected or determined that a part (or part container 44A) is almost depleted in the assembly area 24, and more particularly in a certain assembly cell 34, and needs to be restocked in a certain assembly cell 34, then this continuous event is initiated by the local and / or central control system 326, 616. This detection or determination of whether a certain part needs to be replenished in a certain assembly cell 34 can be made by sensors (not shown) located in the assembly cell 34, by quantitatively monitoring the usage or amount of parts used in the progress of a build, by manual observation by a human operator or by visual monitoring, such as by a video camera or video imaging device, by a predetermined time period, and / or other ways or processes known to those skilled in the art.

[0077] In an example, an example vehicle 40A is autonomously moved, positioned and aligned at a predetermined assembly cell 34 of the assembly area 24 where replenishment of a full container 44A, 204 of parts is required to support assembly operations in the assembly cell 34. In an example, an empty container 44A, 214 is positioned in the assembly cell 34. In the example shown in FIG. 12A, the second support 114 of the transfer vehicle 40A is used to engage the empty container 44A, 214 in the rack channel 56 and to onboard the empty container 44A, 214 to the transfer vehicle 40A. As shown in FIGS. 4 and 12C, the transfer vehicle 40A with the on-board full container 44A, 204 and empty container 44A and 214 is then automatically indexed or moved downstream in the x-direction 64 to position and align the first support 110 and full container 44, 204 to replace the just removed empty container 44, 214. The transfer vehicle 40A transfers and deposits the full container 44A, 204 into the rack channel 56 in the assembly cell 34. The transfer vehicle 40A then returns along the material channel 50 to the storage rack 162 to deposit the empty container 44A, 214 in the second area 210 of the storage rack 162 and rack channel 56 or other predetermined area in the consolidated storage area 20 as described above.

[0078] In an example, the transfer vehicle 40A is then instructed, e.g., by the controller 80, 326, 616, to index, position, align and pick up another full container 44A, 204 from the storage rack 162 with the first support 110 in the manner generally described for delivery to the assembly area of the cell requiring replenishment of that part. Although described for autonomous vehicle 40A, vehicles 40C and 40E with first support 110 and second support 114 can be used equally for the described actions and operations.

[0079] In the case of a transport vehicle using a single first support 110, e.g., vehicles 40B or 40D, a second or companion single support device 40B, 40D can be moved in coordination, in tandem with the full container 44A, 204 or empty container 44A, 214 and to extract or deposit the full or empty container in the storage rack 162 or assembly area 24 as generally described. Using the described equipment and processes provides for more efficient, nearly continuous or uninterrupted supply of parts to support assembly operations. It also provides for efficient removal and logistics handling of empty containers 44A, 214 from the assembly area 24.

[0080] It should be understood that alternative storage rack structures 162, sizes, configurations, orientations, components, features, automation devices, and functionality suitable for the particular application and performance requirements known to those skilled in the art for supporting, monitoring, and moving containers 44A can be used. As an alternative example, the storage rack 162 can be configured to separate full containers 44A, 204 from empty containers 44A, 214 in a manner different than described and illustrated. In one example, a separate rack (not shown) located alongside the rack 162 can be dedicated to receiving empty containers 44A, 214, while the rack 162 can be dedicated to full containers 204.

[0081] Referring to FIGS. 2, 13, and 14A, B, an example of a collective storage area 20 is shown that includes small part containers, small parts and / or bulk parts, a storage area 166 (collectively, small part container area). In this example, the small part container area 166 is located downstream of the large part container area 160 and upstream of the assembly area 24. In an example, the area 166 is useful for generally smaller parts or sub-components 246 that do not have a custom or dedicated storage rack or dunnage 44A as compared to the parts stored in the large part container area 160. In an example, these smaller parts 246 can be shipped into the site 12 in containers 44B of small or smaller size (possibly still a relatively large size) and include, for example, many smaller parts 246 loosely placed therein. As best seen in the FIG. 13 example, multiple small part containers 44B can be placed in the y-direction 140 at a location away from the rack aisle 56. In an example, the small part containers 44B can be positioned in the area 166 by the second transfer vehicle 224 as described above. Other devices or vehicles, such as pallet jacks or carts, can be used as known to those skilled in the art.

[0082] Referring to the example of the small part container storage area 166 of FIGS. 13 and 14A, the plurality of part containers 44 can include a plurality of transfer pallets 244 for receiving parts 246 and positioning and orienting the parts 246 relative to the pallets 244. In an example, each transfer pallet 244 includes a rigid frame 250 and a base support surface 254 for supporting the parts 246. In an example of the system 10, one or more, or a plurality of transfer pallets 244 are placed in the rack aisle 56 directly adjacent to the material aisle 50 for extension or interfacing communication by the transfer vehicle 40 as described above.

[0083] In an example, the base support surface 254 includes a geometric grid pattern of mounting grid holes 260, for example, holes spaced every 100 millimeters (mm) in x and y geometric dimensions or directions, across the surface. In an example, one or more clamps or other tools 264 are mounted in selected mounting grid holes, providing accurate and precise positioning of components 246 relative to the pallet 244. In positioning the pallet 244 in an accurate and precise location in the assembly cell 34, programmable robots and / or other automated equipment can engage the components 246 and move them quickly into the assembly cell 34 for processing, for example, welding the positioned components to a step-assembly vehicle or other product. Other configurations, components, shapes, sizes, surfaces, and component positioning devices for the transfer pallet 244 can be used to accommodate particular applications and components known to those skilled in the art. Component support and holding devices other than the pallet 244 can be used. In an example not shown, small component containers 44B can be positioned in the storage area 166 shelf channels 166 and engaged, transported, and deposited in the assembly area 24 to support assembly runs for the storage shelves 162 and large component containers 44A.

[0084] Referring back to the FIG. 13 example, a human operator 268 can remove components 246 from the small containers 44B and position the components 246 to predetermined locations on the pallet 244 for use by the assembly cell 34 as described above. In an alternative example (not shown), automated equipment, for example, programmable robots and associated end effectors, can be used to transfer the components 246 from the small component containers 44B to the pallet 244. Other devices and methods can also be used to transfer the components 246 from the small component containers 44B to the transfer pallet 244 to accommodate particular applications and performance requirements known to those skilled in the art. Alternatively, the pallets 244 with components 246 stored therein can be pre-assembled at a supplier and shipped to a site for use as described above. It is further understood that any of the transfer vehicles 40A-40E can be used to engage, transport, and deposit the containers 44B or pallets 244 in the manner described.

[0085] Referring to the example of Fig. 13, an example of a consolidated storage area 20 is shown, including or consisting of a consumable material storage area 170. In this example, the consumable material area 170 is located downstream of the small parts container area 166 and upstream of the assembly area 24. In the example, parts in the form of consumable materials 284 discussed above, such as bulk fasteners, lubricants, sealants and other materials used directly in the assembly operation, or indirectly by the equipment in the assembly operation, can be temporarily stored in the y-direction spaced apart from the rack aisle 56 and then positioned and aligned in the rack aisle 56 of the storage area 170, as described for the area 166. These parts 284 can be transported to the containers 44 of the warehouse area 16 of the site 12, such as including for example on conventional pallets or other support devices, and transported into the area 170 by the second transport device 244 or other devices as described above.

[0086] In one example, a human operator 268 transfers the full containers of consumable materials 284 to predetermined locations in the rack aisle 56 to facilitate engagement by the transport vehicle 40. Alternatively, a second transport vehicle 224 or automated equipment such as robots or lifts, places the consumable materials 284 in the rack aisle 56 to await engagement by the transport vehicle 40 according to the predetermined assembly or component schedule. In another example, the consumable materials 284 are positioned on transport pallets 244 that are positioned in the rack aisle 56, as generally described for the area 166.

[0087] In one example of the system 10, the small parts 246 and / or consumable materials 284 located in the rack aisle 56 are selectively engaged by the transport vehicle 40 in a manner similar to that described for the large parts containers 44A and transported to the assembly area 24 according to the predetermined assembly schedule and replenishment requirements of the assembly area 24, as further described below. It will be appreciated that other configurations, sizes, locations and logistics directions or organization of the areas 166, 170 and / or materials 246, 284 can be used to suit particular applications and performance specifications known to those skilled in the art. It will be appreciated that any of the storage areas 160, 166 and / or 170, alone and / or in combination with one or both of the other storage areas 160, 166 or 170, can be used with one and / or combination of the transport carriers 40A-40E to suit particular applications and performance requirements known to those skilled in the art.

[0088] Referring to FIGS. 2, 3, 15 and 16, the example system 10 includes an assembly area 24 having one or more assembly lines 26 (nine are shown in FIG. 1) and sequentially positioned assembly cells 34 as described above (one assembly line and two assembly cells 34A, 34B are shown in FIGS. 2, 15 and 16). In the example assembly area 24, an assembly area rack aisle 56 extends into at least a portion of the assembly area 24, and in the example shown, extends into the entire assembly area 24 as shown. In an example, the rack aisle 56 extends through the assembly area 24 in substantially linear alignment from the consolidated storage area 20 as generally shown and best seen in FIG. 3. In an example, the rack aisle 56 is continuous. In alternative examples (not shown), the rack aisle 56 in the assembly area 24 is not continuous and / or is not in linear alignment with the rack aisle 56 in the consolidated storage area 20. In the example described and shown in the assembly area 24, the rack aisle 56 is positioned directly adjacent and parallel to the material aisle 50, and further positioned adjacent to, or in communication with, each assembly cell 34 as shown in FIGS. 15 and 16. Other locations, positions and / or orientations of the rack aisle 56 in the assembly area 24 can be used to suit application and performance specifications known to those skilled in the art.

[0089] As best seen in FIGS. 15 and 16, in an example of the assembly site 12 and system 10, each assembly line 26 includes a travel path of a conveyor or assembly line 30 that extends through one or more, at least two or alternatively a plurality of assembly cells 34. In an example of the assembly line travel path 30, an assembly pallet 304 is sequentially positioned and moved along the assembly travel path 30. One example of an automated assembly pallet system is the VERSAPALLET system assigned to the present assignee and described in U.S. Patent 6,966,427, incorporated herein by reference. In an example, each assembly pallet 304 supports a product that is sequentially and progressively assembled by automated equipment described below. In an example, at least one product is a vehicle body structure vehicle. In an example, at least one product is a first product and a second product that is different from the first product. In an example, the first product is a first vehicle model and the second product is a second vehicle model.

[0090] It will be appreciated that alternative assembly cells 34 and automated equipment other than assembly pallets can be used. For example, overhead conveyors such as those described in U.S. Patent Nos. 6,799,673, 6,564,440, 6,719,122 and 7,108,189 assigned to the present assignee and incorporated herein by reference, can be used and assembly systems and incorporated herein by reference. Other assembly line conveyors and systems known to those skilled in the art can be used.

[0091] In example assembly cells 34A, 34B as shown in FIGS. 15 and 16, each assembly cell 34, A, 34B includes an automated assembly system 310 including a plurality of automated, programmable, multi-axis robots 314 positioned along or parallel to the assembly travel path 30 as generally shown. The robots 314 can be overhead and / or floor mounted. The robots 314 are in communication with a control cabinet 320 which is in communication with a local and / or centralized control system 326, 616 including one or more components shown in FIG. 18 and further described below. The automated assembly system 310 and control system 326, 616 include programming stored in memory to support a predetermined assembly build run sequence, for example, for at least one product, or alternatively for a plurality of different products, and to control and move the robots 314 and other automated assembly equipment to perform the predetermined assembly build run.

[0092] In example assembly cells 34A, 34B, a scaffolding structure 330 including support surfaces 334 for supporting the robots 314 and control cabinet 320 are shown in general use. An example of the structure 330 and robots shown is described in U.S. Patent No. 8,201,723 assigned to the present assignee and incorporated herein by reference. In an example, the support surfaces 334 can further support moveable support surfaces or technical trays 328 including predetermined equipment for supporting the assembly run, for example, consumable materials. One example described is incorporated herein by reference in U.S. Patent No. 10,131,388 assigned to the present assignee.

[0093] In the example assembly area 24 shown in FIG. 15, a consumable material station 350 is positioned between two assembly cells 34. In an example, an overhead rack aisle 56A is positioned above the floor and is aligned in the lateral y-direction 140 with the assembly area rack aisles 56 (described in general above at the floor level of the facility). In an example (not shown), the consumable material station 350 is positioned adjacent at least one of the assembly cells 34A or 34B. The consumable material station 350 is operable to provide consumable materials, for example, to indirectly support an assembly run by the assembly equipment in the assembly cells 34A and / or 34B. For example, where the assembly cells 34 perform a joining operation by the robots 314 with adhesive applicator end effector actuators to apply a bead of adhesive, the consumable material station 350 provides a pre-staged supply of consumable materials in the vicinity of the assembly cells to provide a continuous replenishment of adhesive to support the assembly run.

[0094] In an example consumable material station 350, the transfer vehicle 40 delivers containers 44 of material 284 for storage in the rack aisle 56A in the manner described above. Removal of the consumable material 284 from the empty containers 44 is performed by the transfer vehicle 40 as described above.

[0095] It should be appreciated that the consumable material station 350 can assume alternative configurations, positions, orientations, and directions relative to the assembly cells 34 and assembly area 24 to accommodate particular application and performance requirements. For example, the consumable material station 350 can be positioned at an upstream end or a downstream end (not shown) of the assembly lines 26, or a selected area of the assembly lines 26. In another example (not shown), the station 350 can be positioned outside of the assembly area 24. It should be appreciated that the assembly area 24 and system 10 can not include a consumable material station 350.

[0096] In the FIGS. 15 and 16 example, the one or more assembly cells 34A, 34B can also include a transfer robotic device 370 including one or more, or a plurality of transfer robots 314A (one shown) positioned transversely along the y-direction 140 and extending along the x-direction 64 between the assembly area rack aisle 56 and the assembly travel path 30. In an example, the transfer robots 314A can remove a component from a component container 44A, 44B or tray 244 positioned in the assembly area rack aisle 56 for placement and orientation on another device, such as a fixture or tray 244A positioned directly within the travel path of the automated assembly system 310 and / or assembly path 30 and within communication range of the assembly robots 314. In an example, the transfer robotic device 370, the transfer robots 314A are positioned on a mobile base (not shown), such as a conveyor or automated guided vehicle (AGV) that moves the transfer robots 314A along the x-direction 64 to selectively align with a next predetermined component container 44A, B or tray 244 for engagement, manipulation, and transfer of the component from the container 44A, 44B or tray 244 onto the fixture or tray 244A directly adjacent the travel path of the assembly path 30.

[0097] It should be appreciated that the transfer robots 314A can transfer the engaged components directly from the containers 44A, 44B and / or trays 244 to the automated assembly device 310 and / or assembly travel path 30 for, for example, welding the components to a step- built vehicle or at least one product traveling along the assembly travel path 30. In an alternative example, the transfer robots 314A can engage the components and position the components in their 3-dimensional coordinate space (x, y, z), and the assembly robots 314 can directly engage the components and transfer the components to the assembly travel path 30 for processing. It should be appreciated that the transfer robots 314A and / or conveyor device or area 370 can use alternative devices and / or equipment, and / or assume other configurations, positions, and operations other than described to accommodate particular application and performance requirements.

[0098] In an alternative example (not shown), the assembly area rack aisle 56 is located directly adjacent to, or in traffic communication or reach of, the assembly robots 314 in the automated assembly system 310. In this example, the assembly robots 314 can articulate, engage and transfer components directly from the containers 44A, 44B and / or the trays 244 to the automated assembly system 310 and / or the assembly travel path 30 for direct assembly processing without the need for the transfer area 370 or the transfer robots 314A. It will be appreciated that any of the individual equipment, devices and / or processes described above can be used in combination with or selected for use with other separately described equipment, devices and / or processes to suit the particular application and performance specifications of the assembly area 24 or site as known to those skilled in the art.

[0099] In the exemplary system and method 10, one or more, or a plurality of transfer vehicles 40 supporting engaged full component containers 44 are selectively moved along the material aisle 50 into the assembly area 24, best as shown in FIGS. 15 and 16. The component containers 44 (shown 44A, 44B) are selectively positioned in the assembly area 24 in accordance with the operation of the assembly cells 34. For example, as best seen in FIG. 16, a full large component assembly container 44A is positioned by a transfer vehicle 40 as described above into the assembly cell 34B rack aisle 56. As best seen in FIG. 15, a full transfer tray 244 supporting components 246 is similarly positioned into the assembly cell 34A rack aisle 56 of a transfer vehicle 40 as described above. As described above, consumable assembly materials 284 are positioned into the consumable material station 350 rack aisle 56A. It will be appreciated that the component containers 44A, B and trays 244 can be placed in different locations in the assembly area 24 other than the rack aisle 56 to suit the particular application and performance requirements as known to those skilled in the art.

[0100] In the system 10 example, the transfer vehicle 40 extends the first support 110 or the second support 114 in the y-direction 140 upon arrival at the intended destination or location in the assembly area 24 to position the component container 44, tray 244 or consumable material 284 into the rack aisle 56, 56A and then separates it for storage in the rack aisle 56 or 56A in accordance with the on-board component container 44, tray 244 or consumable material 284. In an example in which the transfer vehicle 40 includes the first support 110 and the second support 114 (e.g. FIGS. 5A, 6A and 7A), full component containers 44 and trays 244 or consumable materials 284 can be placed in the rack aisle 56, 56A and empty component containers 44, trays 244 or consumable materials 284 can be removed from the assembly area 24 in one visit or cycle of the aforementioned transfer vehicle 40. As previously described, such visits or cycles can also occur in the staging area 20.

[0101] These described devices and processes greatly increase the overall efficiency and throughput of the transfer vehicles 40, the consolidated storage areas 20, the assembly areas 24, and the system 10. The design and utilization of the material aisles 50 and transfer vehicles 40, the rack aisles 56, 56A, and the pedestrian aisles 60 also reduces the amount of floor or site footprint required to support high volume assembly operations while increasing efficiency and unit assembly or throughput. The system 10 further provides a high degree of automation through the use of autonomous transfer vehicles 40 in combination with automated assembly devices and systems 310.

[0102] While the above described system 10 example has described the assembly area 24 including a single assembly line 26 for example purposes and convenience, it should be understood that the assembly area 24 can include at least one assembly line 26, or multiple assembly lines 26. In the example shown in FIG. 1, the assembly area 24 of the system 10 includes multiple assembly lines 26 (not shown), each including multiple assembly cells 34. In this example, all of the multiple assembly lines 26 are oriented to extend substantially straight in the x-direction 64 and are substantially parallel to one another. In the example, each assembly line 26 includes a dedicated assembly line rack aisle 56 (or assembly area rack aisle) as described above and best seen in FIGS. 3, 15, and 16.

[0103] In the FIG. 1 example, each assembly line 26 also includes a dedicated (or assigned) consolidated storage area 20 having a storage area rack aisle 56 aligned with the assembly area rack aisle 56 described above. In an example, the dedicated storage area 20 will include only components for a particular assembly line 26. As described above, the storage area 20 can include one or more or all of the areas 160, 166, and / or 170. In the example, when multiple assembly lines 26 are used, a dedicated material aisle 50 is used for each assembly line 26 located proximate to the rack aisle as described above. In an example, a dedicated pedestrian aisle 60 can also be used. In the example, for each assembly line material aisle 50, at least one of the multiple transfer vehicles 40, or multiple of the multiple transfer vehicles 40, are moved back and forth between the respective dedicated storage area 20 and the corresponding assembly area 24 or assembly line 26 to engage, transfer, and disengage the component containers 44 as described in the above example.

[0104] In an alternative example of FIG. 1 (not shown), one material passageway 50 and transfer vehicle 40 can be "shared" between two adjacently positioned assembly lines, rather than having two dedicated material passageways 50 (one per assembly line 26) and transfer vehicle 40 for each material passageway 50. In this example, the transfer vehicle 40 selectively engages and transfers components to a selected shared assembly line 26 to support assembly of at least one product in the respective assembly line 26 according to the progress of the components. In this example, a single collective storage area 20 can also be "shared" between two assembly lines 26 (as opposed to a dedicated storage area 20 per assembly line 26) in a similar manner. Other configurations of the system 10 can be used to accommodate applications or performance specifications known to those skilled in the art.

[0105] Referring to FIG. 17, an example of the system and method 10 includes a vision detection safety system 390. In an example, the safety system 390 is positioned in the assembly area 24, such as the backup assembly area 24A and assembly cell 34C, as shown. In this example, one or more, or a plurality of sensors 394 are used to identify predetermined detection zones, such as a first zone 400, a second zone 404, and a third zone 408, as generally shown in FIG. 17. The sensors 394, 428 are in communication with the local or centralized control system 326, 616 (including components shown and generally described in FIG. 18). As described above, the local or centralized control system 326, 616 is also in communication with the automated equipment of the assembly area 24, such as the vehicles 40, robots 314, 314A, and automated assembly systems 310.

[0106] In an example of the safety system 390, the first zone 400 defines an area in which movement of objects, such as human operators or other parts of equipment, such as the transfer vehicles 40, will not change operations in the assembly area 24. In an example using FIGS. 15 and 16, the first zone 400 can include a field of view or cover the pedestrian walkway 60 where, for example, human operators (not shown) are able to move and oversee operations in the collective storage area 20 and assembly area 24. In an alternative example, the first zone 400 can alternatively or also include the material passageway 50 in which the moving vehicles 40 move, as described above.

[0107] In the FIGS. 15, 16, and 17 examples, detection of movement or an unauthorized object in the second zone 404 by the sensor 394 can trigger an alarm and / or change the component cell 34 or zone 24 component operation. In an example, the second zone 404 can include a field of view or coverage of the material passage 50. In an example, if an unauthorized object or human operator (not shown) is detected in the material passage 50, the movement speed of the automated equipment, e.g., the transfer vehicle 40, the high speed assembly robot 314 / 314A, and / or the automated assembly system 310, can be automatically reduced by the control system 326, 616 to prevent a high speed impact with the detected unauthorized object. Alternatively, detection of an unauthorized object in the second zone 404 can immediately stop all movement and / or operation of all controlled automated equipment 40, 314, 314A, 310 in the assembly cell 34C and / or assembly zone 24A. In an alternative example, the second zone 404 can alternatively or also include or cover the rack passage 56.

[0108] In the FIGS. 15, 16, and 17 examples, detection of an unauthorized object in the third zone 406 by the sensor 394 can signal a serious or high level alarm and initiate an immediate stop of all automated operation in the assembly cell 34C or assembly zone 24A until the alarm is investigated and resolved / cleared. In an example, the third zone 406 can include the material passage 50, the rack passage 56, and / or the area between the rack passage 56 and the assembly travel path 30 in the y-direction 140. It should be appreciated that the zone covered by the field of view or coverage of the sensor 394 can include one or more of the above passages or zones, or alternative or additional zones, to accommodate particular application and / or site safety requirements as known to those skilled in the art.

[0109] In an example of the system 390, the sensors 394, 428 can be lasers, ultrasonic, infrared, or otherwise operable to detect one or more of selected objects or movement of objects within a field of view or coverage area of the sensors 394. Other devices, such as video cameras or other image capture devices, can be used to detect the presence of equipment or other objects within a respective area or unauthorized movement. In an example, the system 390 and / or sensors 394, 428 can detect and distinguish between authorized equipment or items, and unauthorized equipment or items in respective areas. For example, a sensor 394 having a field of view covering the material passageway 50 can be operated to distinguish between a transfer vehicle 40 that is allowed to move in the material passageway 50 under normal operation and a human operator (not shown) that is not allowed to move in the material passageway 50 under normal operation. This can likewise be used for the rack passageway 56 and the automated assembly system 310. Spare devices (not shown), such as radio frequency identification (RFID) tags or other devices, can be affixed to objects that are normally allowed to be located in an area that would not trigger or alert an alarm in the respective area, and would not slow down or stop operation when detected. For example, movement of a container 44, a pallet 244, or a robot 314, 314A in the rack passageway 56 would not trigger an alarm or alert to slow down or stop operation in the assembly cell 34C or assembly area 24A. The system 390 can also be used in a similar manner in the consolidated storage area 20. Other systems 390, sensors 394, devices, control systems, and / or operations for use as a vision security system in combination with the system 10 described can be used in a manner known to those skilled in the art.

[0110] Referring to FIG. 18, an example of a transfer vehicle 40 control system 80, a local control system 326, and / or a central control system 616 (collectively, the local control system 326, unless otherwise specified) is shown. The control system 326 includes one computing device or multiple computing devices that work in concert. Exemplary control system computing devices include common hardware components, including but not limited to a central processing unit (CPU) 420, a data memory storage device 424, one or more controllers (including but not limited to a programmable logic controller (PLC)) 436, input / output devices 440, transmitters and receivers 444 for transmitting and receiving hardwired or wireless data signals, actuators 432 (e.g., electric motors) and sensors 86, 428. These hardware components communicate with one another in data signals, either through hardwired connections or wireless communication protocols, through a bus 450 or other suitable hardware. Other hardware components, including additional input and output devices 440, are included to accommodate specific applications and performance specifications known to those skilled in the art. Examples of input devices include, but are not limited to, touch-sensitive display devices, keyboard imaging devices, and other devices that generate computer-interpretable signals in response to user interaction. Examples of output devices include, but are not limited to, display screens, speakers, alarm lights, and other audio or visually perceptible devices. The control system 326 is powered by a power source 406, such as a rechargeable battery or conventional electrical power provided by the assembly site 12.

[0111] The exemplary processor 420 can be any type of device capable of processing, calculating, or running information, including but not limited to digital information, that is currently known or that can be developed in the future. One example of a processor is a conventional central processing unit (CPU).

[0112] The exemplary data storage device 424 can include a device that stores information, including but not limited to digital information, for use by the processor 420 either immediately or in the future. Examples of memory storage devices include one or both of a random access memory (RAM) or a read-only memory (ROM) device. The memory storage device can store information such as program instructions executable by the processor 420 and data stored by the processor 420 and called or retrieved by the processor 420. In addition, a portion of an operating system for the computing device and other applications can be stored in the data storage device 424. Non-limiting examples of memory storage devices for the storage device 424 include a hard disk drive or a solid state drive. Alternatively, a portion of the stored information can be stored in the cloud (a remote storage device or data center) and selectively retrieved through a wireless protocol.

[0113] In one example of the system 10, the control system 326 includes a suitable software operating system and pre-programmed software to perform the predetermined actions, functions or operations of the system 10 described herein. The operating system and software can be stored in the data memory storage device 424 and processed and executed by the processor 420 through the controller 436 and actuators 432.

[0114] In one example, the system 10 or components thereof, such as the transfer vehicles 40, can receive operational instructions and commands through data signals transmitted wirelessly in real-time from the local or central control system 326, 616 or other local or central control system. Examples of communication networks that can be used in the site 12 can include, but are not limited to, a Local Area Network (LAN) or a Campus Area Network (CAN). Examples of wireless communication networks, systems and protocols that can be used with the system 10 include wireless routers for communication based on IEEE Standard 802.11 (also known as wi-fi). Other wireless communication protocols can be used, such as Bluetooth. Other wired communication systems and components for communication can be based on IEEE Standard 802.3 (also known as Ethernet) and can be used in certain applications. Other forms of communication networks, wired and wireless communication protocols, systems and devices known to those skilled in the art can be used.

[0115] The autonomous or automated driving operational mode of the transfer vehicles 40 described above can be achieved through the use of one or more sensors 86, 428 on-board the vehicles 40A, B, E, such as omnidirectional laser radar (light imaging, detection and ranging), on-board processing of received sensor data by the transfer vehicles 40, and on-board execution of commands by the on-board control system 80 and actuators 432 to navigate and move the vehicles 40 along a travel path. Other types and forms of sensors 86, 428 and location monitoring and navigation systems can be used, including but not limited to Global Positioning Satellite (GPS) systems, triangulation devices, ultrasonic sensors, laser sensor systems, radar, proximity sensors and / or visual imaging devices or systems known to those skilled in the art. As previously described, the instructions and commands for moving and directing each vehicle 40 can be received by the individual vehicles 40 from the local and / or central control system 326, 616, alternately or in combination, for execution by the respective vehicle 40 control system 80.

[0116] As described and shown above, the control system 326 also communicates with automated equipment in the consolidated storage area 20 and / or the assembly area 24. For example, sensors and actuators can be activated and controlled to move or arrange containers 44 in the rack 162 rack channels 56, as well as control and move the conveyors of the robots 314, 314A and the automated assembly system 310 to move progressively assembled vehicles or at least one product through the assembly area 24 in sequence.

[0117] Referring to FIG. 19, an example of a method for assembling a material flow 500 is shown. In an example method, step 510 includes storing a plurality of component containers 44 containing at least one component in a consolidated storage area 20. As described above, an example consolidated storage area 20 includes a large component container area 160, a small container component area 166, and a consumable assembly material area 170 to temporarily store and organize components and associated containers 44 for use in assisting assembly operations. As described above, the container components can include 44A, 44B, a transfer pallet 244, and a conventional pallet (for consumable materials) or other devices or structures operable to support and assist in the transfer of containers or components.

[0118] In an alternative and optional step 515, components and / or subcomponents 426 from the subassembly area 166 can be transferred from the containers 44A or 44B to the pallets 244, as described above.

[0119] In an example step 520, selected component containers 44 are selectively positioned and arranged in the consolidated storage area 20 in the rack aisle 56 directly adjacent to the material aisle 50, as described above. It will be appreciated that the containers can be placed outside of or in different locations from the rack aisle 56 described and shown herein.

[0120] An example step 530 includes positioning a transfer vehicle 40 along the material aisle 50 adjacent to a predetermined rack aisle 56 including arranged containers 44.

[0121] An example step 540 includes engaging a selected one of the plurality of full containers 44, 204 by the transfer vehicle 40. In an example, the transfer vehicle 40 extends the first support 110 or the second support 114 into the rack aisle 56 in the y-direction 140 to engage and secure to the predetermined, positioned, arranged, and aligned full component container 44, 204 on the vehicle 40. In an example where the transfer vehicle 40 includes the first support 110 and the second support 114, an empty / depleted component container 44, 208 is placed in the component storage area 20 immediately before or after the transfer vehicle 40 engages the full component container 44, 204. As previously described, using a vehicle 40 having a first support 110 and a second support 114 allows the same vehicle 40 to engage a full or empty container, quickly index along the x-direction of the material aisle 50, and separate and deposit other empty or full containers into a storage rack 162 of the rack aisle 56, or alternatively in the assembly area 24 rack aisle 56, as described above. In an alternative example, the transfer vehicle 40 includes only the first support 110, the second transfer vehicle 40, or accompanying the transfer vehicle 40 can engage or deposit other full or empty containers into the appropriate rack aisle 56.

[0122] Exemplary step 550 includes transporting the engaged full component container 44, 204 from the consolidated storage area 20 to the assembly area 24 (or alternatively transporting the empty container 44, 214 from the assembly area 24 to the consolidated storage area 20). In an example, the transfer vehicle 40 moves only along the material path 50 in the x-direction 64 as described above.

[0123] Exemplary step 560 includes storing the full component container in the rack aisle 56 of the assembly area 24 (or alternatively storing the empty container in the rack aisle 56 of the storage rack 162) as described above. In an example, the transport device 40 extends the first or second support to the rack aisle 56 in the y-direction 140.

[0124] In exemplary and optional step 565, where the transfer vehicle 40 includes the first support 110 and the second support 114, the transfer vehicle 40 can also pick up / engage an empty / depleted component container 44 located in the assembly area 24 before returning to the consolidated storage area 20, thereby engaging another full component container 44, 204 in the manner generally described above. In an alternative example, the transfer vehicle 40 includes only the first support 110, and a second or companion transfer vehicle 40 can engage an empty container 214 in the assembly area 24 rack aisle 56, transport the empty container to the consolidated storage area 20 in coordination, and store the empty container in the rack aisle 56 of the storage rack 162 as described above.

[0125] Although the method 500 is described as engaging, transporting, and detaching a full container from the rack 162 of the storage area 20 to the assembly area 24, it should be understood that the method 500 is equally used to transfer a full container from the storage areas 166 and / or 170 to the assembly area 24 in a similar manner. It is further understood that the method 500 is equally used to engage, transport, and store an empty container from the assembly area 24 to the consolidated storage area 20, including each of the areas 160, 166, and 170, in a similar manner.

[0126] In exemplary step 570 shown in FIG. 19, and as seen and described in FIG. 16, components are removed from the containers 44A, 44B or trays 244 placed in the rack aisle 56 of the assembly area 24 and either transferred to a tray 244A located directly adjacent to the assembly travel path 30 or directly into the automated assembly system 310 and / or assembly travel path 30 for assembly operations, generally as described above. Where components are first transferred to the tray 244A, the assembly robot 314 selectively engages the components located on the tray 244A and transfers them to the automated assembly system 310 and / or assembly travel path 30 for use. As described above, one or more, or multiple robots 314A, 314 can be used to transfer components from the rack aisle 56 to the automated assembly system 310 and / or assembly travel path 30 for use.

[0127] The exemplary method 500 can include additional steps, removal of steps, and / or a different order or sequence of steps than described and illustrated to affect the apparatus and method of the system 10 as known to those skilled in the art.

[0128] Referring to FIGS. 20 and 21, an example of an assembly logistics monitoring method 600 useful in the system and method 10 is illustrated. In the example system and method 600, the above described logistics apparatus and operations of the system 10 at the site 12, including the assembly operations in the assembly area 24, are fully automated or substantially automated.

[0129] Through the use of the above described and briefly described below multiple sensors 428 and monitoring apparatus, the location and movement of the component containers 44, the storage and / or inventory of components in the storage area 20, and / or the assembly operations in the area 24 are continuously or periodically monitored and data transmitted to a central control center described below. Through the monitoring, collection and analysis of the logistics data, real time visual and analytical models of the site 12 and system 10 can be viewed and monitored to detect whether the system 10 and all subsystems, such as the consolidated storage area 20, the transfer vehicles 40, the assembly area 24, are operating within predetermined parameters. The system and method 600 can be implemented in one or more or each aspect of the above described logistics operations, from the component entry in the loading dock 16, to the storage and movement in the consolidated storage area 20, the transfer between the storage area 20 and the assembly area 24, and the assembly operations in the assembly area 24.

[0130] Referring to FIG. 20, an example of a site 12 includes the above described system 10, including the loading dock 16, the consolidated storage area 20 and the assembly area 24. The exemplary assembly area 24 is described above, including one or more, or multiple assembly lines 26. In one example of the system 600, the site 12 includes a central control center 616, including a logistics and assembly monitoring and simulation system and apparatus 620. The system 620 can include a commercially available product manufacturing and / or assembly simulation software program that allows for detailed monitoring and analysis of automated industrial equipment and processes.

[0131] As shown in FIG. 21, each of the consolidated storage areas 20 and assembly areas 24 (only one assembly line 26 is shown) can include one or more local control and monitoring devices 326 (three are shown). The components, hardware, operating systems, and software for the control systems 80, 326 are described above, as shown in FIG. 18. The local control devices 326 are connected and / or monitor a plurality of sensors and monitoring devices (not shown) in data signal communication, wireless, and / or hardwired as described above, with the automated devices described above, such as sensors and actuators in the storage racks 162, transfer vehicles 40, robots 314, 314A, and / or automated assembly systems 310. It will be appreciated that the local control devices 326 can communicate with additional or alternative sensors or automated devices in the system 10.

[0132] Examples of sensors 428 and monitoring devices can include electronic, physical, location, visual imaging cameras and video devices, and other sensors and devices to detect and / or monitor predetermined conditions of the automated devices and transmit signal data to the local 326 or central control center 616 for analysis and monitoring. Other sensors and monitoring devices are used to detect location and physical movement, time, and / or other metrics to accommodate particular automated devices and assembly processes known to those skilled in the art.

[0133] In the example system and method 600, the logistics signal data collected by the sensors and / or local control devices 326 is transmitted to the central control center 616. The control center 616 and monitoring system 620 can include one or more of the devices, hardware, operating systems, and software described and illustrated in FIG. 18. One example of the monitoring or simulation system 620 can include a computer and visual monitor for visually displaying one or more aspects of the logistics operation and data received from the operation of the system 10. In the example system 600, the logistics and assembly operations of the site 12 can be visually monitored and analyzed and calculations can be made to monitor whether the logistics and / or assembly operations are being performed within predetermined parameters stored in the storage devices 424 (illustratively shown in FIG. 18). In one example, a virtual digital model of one or more operations of the system 10 or the entire site 12 can be generated and / or simulated in order to monitor the processes and devices in real time according to predetermined efficiency and performance standards / goals established for the system 10.

[0134] In one example of the system 600 shown in FIG. 20, one or more of the monitoring and / or simulation activities described above in the control center 616 can be performed in an off-site / remote site 640. In addition, the local or central control devices 326 and / or 616 can communicate with an off-site / remote cloud data center 646 (which is in communication with the off-site facility 640). Other computing centers and communication devices and systems are suitable for use in applications known to those skilled in the art.

[0135] It should be understood that the system and method 600 can include additional or alternative devices, as well as additional or alternative method steps, or steps in different order or sequence in time, to suit particular application and performance requirements known to those skilled in the art.

[0136] While the application has been described in connection with certain embodiments, it is to be understood that the application is not limited to the disclosed embodiments, but instead, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which should be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures.

Claims

1. An assembled material flow system comprising: a consolidated component storage area operable for temporarily storing a plurality of component containers, each component container supporting at least one component, the storage area having a storage area rack lane extending in an x-direction; an assembly area positioned downstream of the storage area, comprising: at least one assembly line operable for assembling at least one product, the at least one product comprising at least one component; and an assembly area rack lane extending in the x-direction positioned in alignment with the storage area rack lane; a material lane positioned directly adjacent and parallel to the storage area rack lane and the assembly area rack lane; and a plurality of transfer vehicles selectively and reciprocally moving along the material lane between the storage area and the assembly area, each of the transfer vehicles independently operable for selectively engaging at least one of a full or empty component container in the storage area rack lane or the assembly area rack lane, transferring the engaged at least one full or empty component container between the storage area and the assembly area, and selectively disengaging the at least one full or empty component container in the storage area rack lane or the assembly area rack lane to support assembly of the at least one product, wherein the component storage area further comprises a large component container storage area having a component storage rack, and, wherein the component storage rack comprises a plurality of carriers defining a presentation row, the carriers being operable for at least one of: placing a full component container in the storage area rack lane for selective engagement by the plurality of transfer vehicles; or receiving an empty component container separated by the plurality of transfer vehicles, and wherein the component storage rack further comprises a plurality of powered actuators in the plurality of carriers, the powered actuators being operable for at least one of: selectively moving a full component container in a corresponding carrier toward the presentation row; or selectively moving an empty component container in a corresponding carrier toward an exit row.

2. The system of claim 1, wherein the aligned storage area rack lane and assembly area rack lane are configured in a straight line alignment.

3. The system of claim 1, wherein the component storage area further comprises a small component container storage area positioned adjacent to the large component storage area, the plurality of containers of the small component container storage area further comprising a plurality of transfer trays, each transfer tray selectively positioned in the storage area rack lane being operable for positioning and supporting at least one component in a predetermined position relative to the transfer tray, the supported at least one component defining a full component container.

4. The system of claim 3, wherein each of the plurality of transfer trays further comprises: a base support surface having a precision mounting grid; and at least one clamp mounted in the mounting grid, the clamp being operable for supporting at least one component at a precise position relative to the transfer tray. ​ 5. The system of claim 1, wherein the component storage area further comprises a consumable material storage area, the consumable material storage area positioned adjacent to the large component container storage area, the consumable material storage area operable to temporarily store and stage consumable materials to support assembly of the at least one product.

6. The system of claim 1, wherein at least one assembly line of the assembly area further comprises: a first assembly cell extending in the x-direction along the assembly line; and a second assembly cell in assembly communication with the first assembly cell, each of the first assembly cell and the second assembly cell comprising an assembly travel path and a portion of an assembly area rack aisle aligned with the storage area rack aisle, each assembly cell rack aisle positioned in the y-direction from the assembly travel path, the respective assembly cell rack aisle portion operable to selectively receive full component containers from a plurality of transfer vehicles comprising predetermined components to support assembly operations in the respective first assembly cell or second assembly cell.

7. The system of claim 6, wherein at least one of the first assembly cell or the second assembly cell further comprises a programmable robot operable to selectively engage the predetermined components in the rack aisle portion and transfer the engaged components to the respective assembly cell assembly travel path to support assembly of the at least one product.

8. The system of claim 6, wherein the assembly area further comprises a consumable material station, the consumable material station positioned adjacent to at least one of the first assembly cell or the second assembly cell, the consumable material station having a portion of the assembly area rack aisle operable to receive full component containers of consumable materials from a plurality of transfer vehicles to support assembly operations in at least the first assembly cell or the second assembly cell. The consumable material station is positioned between the first assembly cell and the second assembly cell.

9. The system of claim 8, wherein, 10. The system of claim 1, wherein at least one of the plurality of transfer vehicles further comprises: a first support; and a second support on an opposite side of the vehicle body, each of the first support and the second support operable to independently and selectively engage, support, and disengage component containers.

11. The system of claim 10, wherein the transfer vehicle is autonomous in operation to selectively move along the material aisle and selectively engage and disengage component containers positioned in the storage area and the assembly area.

12. The system of claim 1, further comprising a pedestrian aisle extending in the x-direction, the pedestrian aisle positioned directly adjacent and parallel to the material aisle. At least one assembly line of the assembly area comprises a plurality of assembly lines, each of the plurality of assembly lines comprising a dedicated assembly line rack aisle, wherein the system further comprises for each respective assembly line:

13. The system of claim 1, wherein, a dedicated collective component storage area having a rack aisle aligned with the respective assembly line dedicated rack aisle; a dedicated material aisle; and a dedicated assembly line travel path. At least one of the plurality of transfer vehicles is capable of reciprocating along a dedicated material lane between a corresponding dedicated component storage area and a corresponding assembly line.

14. A method for assembling a material flow comprising: storing a plurality of component containers in a collective storage area, the collective storage area being located upstream of an assembly area operable to assemble at least one product, each component container supporting at least one component is defined as a full component container; selectively placing a predetermined full component container in a storage area rack lane extending in an x-direction; positioning one of a plurality of transfer vehicles in a material lane directly adjacent and parallel to the rack lane; selectively engaging a predetermined one of a plurality of full component containers from the storage area rack lane by the transfer vehicle and removing the full component container from the storage area rack lane; transferring the engaged full component container by the transfer vehicle along the downstream material lane to the assembly area; selectively engaging an empty component container located in an assembly area rack lane by one of the plurality of transfer vehicles, the assembly area rack lane being aligned with the storage area rack lane, and removing the empty component container from the assembly area rack lane; and storing the engaged and transferred full component container by the transfer vehicle in the assembly area rack lane to support assembly of the at least one product, wherein the storage area further comprises a large component container storage area having a component storage rack, and, wherein the component storage rack comprises a plurality of trays defining a display row, the plurality of trays being operable to at least one of: place a full component container in the storage area rack lane by the plurality of transfer vehicles for selective engagement; or receive an empty component container separated by the plurality of transfer vehicles, and wherein the component storage rack further comprises a plurality of powered actuators located in the plurality of trays, the powered actuators being operable to at least one of: selectively move a full component container in a corresponding tray toward the display row; or selectively move an empty component container in a corresponding tray toward an exit row.

15. The method of claim 14, further comprising: transferring the engaged empty component container by the transfer vehicle from the assembly area to the storage area; and storing the engaged and transferred empty component container by the transfer vehicle in the storage area rack lane.

16. The method of claim 15, wherein the transfer vehicle comprises a first support and a second support, one of the plurality of transfer vehicles removing the empty container from the assembly area rack lane comprises the transfer vehicle transferring a full component container from the storage area to the assembly area, the transfer vehicle maintaining engagement with the full component container during engagement and removal of the empty container from the assembly area rack lane.

17. The method of claim 14, further comprising the step of selectively transferring at least one component from a full component container located in the assembly area rack lane by a programmable robot to assemble the at least one product. ​ ​

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